3.7 Air Conditioning (A/C) Contents -...

3.7 Air Conditioning (A/C) Contents 3.7 Model 202 as of M.Y. 1999 and up to M.Y. 1999

Diagnosis PageFunction Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/1Reading Actual Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12/1Version Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14/1Diagnostic Trouble Code (DTC) Memory . . . . . . . . . . . . . . . . 15/1

Electrical Test ProgramComponent Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20/1Connection of Components . . . . . . . . . . . . . . . . . . . . . . . . . 21/1Preparation for Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22/1Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/1

Pneumatic Test ProgramComponent Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31/1Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32/1

Refrigeration System Test ProgramComponent Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41/1

b Diagnostic Manual Climate Control 12/98 3.7 A/C C/1

3.7 Air Conditioning (A/C) Model 202 as of M.Y 1996 Diagnosis Function Test

Preparation for Test

1. Review 11, 12, 14, 15, 20, 21, 23, 31, 33, 31

2. Check condition of fuses F1-4, F1-7, F1-8

3. Check in-car temperature sensor aspirator blower by placing a small pieceof paper (arrow) approximately square over in-car temperature sensor(B10/4) vent grille with ignition ON. If there is sufficient ventilation the paperwill remain on the vent grille, if not check aspirator blower for voltage supplyand function.The after-run time for the blower motor is greater than six seconds.

4. Run engine at closed throttle and operating temperature (approx. 80 oCengine coolant temperature) during entire test (ensure that the shift lever isin P and that the parking brake is engaged).

5. Manually open the center and side air outlets.

6. Ensure that the 2 button is not depressed.

P83.40-0437-11

Figure 1

B10/4 In-car temperature sensor

b Diagnostic Manual Climate Control 12/98 3.7 A/C 11/1

3.7 Air Conditioning (A/C) Model 202 as of M.Y 1996

Diagnosis Function Test

Test step/Test sequence Test condition Nominal value Possible cause/Remedy 1)

O 1.0 Defrost Press 3Temperature selection at random setting

Blower runs with increased speed.Air venting from defroster outlets.A/C compressor engaged.Maximum heat output, 100% fresh air

23 O 8.0, 10.0, 14.0, 15.0, 18.0

O 2.0 Ventilation in coolingmode

Press 8Temperature selection LO

Blower runs with increased speed.Air venting from center and sideoutlets.A/C compressor engaged, no heatoutput.

23 O 8.0, 14.0, 18.0, 19.0, 20.0,21.0, 22.0, 23.0, 24.0,

32 O 3.0

O 3.0 Normal setting inregulating mode

Press 8Temperature selection set at present in-car temperature.

Blower speed decreases.Air venting from defroster outlets, leakair from footwell outlets. A/Ccompressor engaged. Tempered airventing. Duovalve cycles and auxiliarycoolant pump runs.

23 O 9.0, 14.0, 18.0, 19.0, 20.0,21.0, 22.0, 23.0, 24.0,

32 O 1.0, 4.0

O 4.0 Economy not in heatingmode

Temperature selection LOPress 6Press "

Air venting from dash outlets (ambienttemperature)A/C compressor OFF.

23 O 16.0, 19.0, 32 O 5.0

1) Observe Preparation for Test, see 22.


3.7 Air Conditioning (A/C) Model 202 as of M.Y 1996

Diagnosis Function Test

Test step/Test sequence Test condition Nominal value Possible cause/Remedy 1)

O 5.0 Economy in heating mode Temperature selection HIPress 6

Air venting from footwell and sideoutlets left/right. Leak air fromdefroster outlets.Maximum heat output.

23 O 14.0, 15.0, 17.0, 18.0, 19.0,20.0, 21.0, 22.0, 23.0, 24.0,

32 O 1.0

O 6.0 Residual engine heatutilization

Ignition: OFFPress 7Selected temperature > 79 g F (26 g C)

Heated air from footwell and sideoutlets, leak air from defroster outlets.Blower runs at low speed.

23 O 14.0, 15.0, 16.0, 17.0, 18.0,21.0, 22.0, 23.0,

32 O 1.0



3.7 Air Conditioning (A/C) Model 202 as of M.Y. 1996 Diagnosis Reading Actual Values (via A/C Pushbutton Control Module [N22])

i

1. The display window will show in sequence the actual temperature readings, refrigerant pressure,blower control voltage and software status of the A/C pushbutton control module (N22).

2. The temperature control is maintained during the duration of the test.

P83.40-0313-01Figure 1


3.7 Air Conditioning (A/C) Model 202 as of M.Y. 1996

Diagnosis Reading Actual Values (via A/C Pushbutton Control Module [N22])


1. Review 11, 12, 14, 15, 20, 21, 23, 31, 33, 31

2. Ignition: ON

2. Set temperature selection to 72 F.

3. Press 7 for more than 6 seconds.

4. The left side of the display window will alternately display the number0I and the in-car temperature (e.g. 72 gF)

5. By pressing 4 + the next highest test step is displayed (see table).

6. Press 7 to end test program.

Note:

The display will, or OP E if there is an open circuit, CL O if there is ashort circuit.




Display code inN22 window

A Possible cause Test step/Remedy 1)

0I 0I In-car temperature sensor (B10/4) 23 O 4.0

02 02 Outside temperature indicator temperature sensor (B14) 23 O 10.0

03 03 Heater core temperature sensor (B10/1) 23 O 7.0

05 06 Evaporator temperature sensor (B10/6) 23 O 5.0

06 05 ECT sensor (DFI, IFI) (B11/4) 23 O 10.0

07 07 Refrigerant pressure in bar, e.g. 06 g 4 corresponds to 6.4 bar 23 O 8.0

08 08 Refrigerant temperature sensor (B12/1), e.g, 73 g 4 corresponds to 73.4 F 23 O 6.0

09 - Not used -

I0 I3 Blower control voltage, e.g. 08 g 0 (min) - 60 g 0 (max) corresponds to 0.8 - 6.0 volts

23 O 15.0

20 - Control current for auxliary fan e.g. 7 corresponds to 7 mA 23 O 11.0

2I I2 Engine speed, e.g. 00 . . 99 (x 100) corresponds to 9900 rpm 23 O 10.0

22 II Vehicle speed 155 (km/h) 23 O 10.0

23 I4 Terminal 58d e.g. 99 corresponds to 99 % battery voltage -





Display code inN22 window

A Possible cause Test step/Remedy 1)

40 3) Software status e.g. 37 -

4I 3) Software status e.g. 08 -

42 2) Version code 1. number code e.g. 03 -

43 2) Version code 2. number code e.g. dIE = diesel/ bEn = benzin (gas) -

50 - not used -

5I - not used -

52 - not used -

54 I5 On - OFF A/C compressor emergency off signal from engine control module 23 O 10.0

- I6 Compressor WOT cut-off on diesel engines -

1) Observe Preparation for Test.2) Version code menu.3) Control module identification.



Version Coding

Programming

1. Turn ignition OFF.

2. Press 7 and hold.

3. Turn ignition ON.

4. Release 7 :7 LED flashes, all other LEDs are OFF.The function of the A/C pushbutton control module is as in position P.Display readout: - - P

5. Press k as needed to select desired version code (refer to table).

6. To enter version code press 6, the previous version code will be erased.

P83.40-0313-01Figure 1



Version Coding

1. Numerical Value A 1) Preliminary setting

COD New, not yet programmed A/C pushbutton control module

00 Serial interface (K1)

02 With serial interface (K1) and (K2) (as of MY 1997)

08 Refrigerant fill level check switched off (up to MY 1997)

I0 With serial interface (K1) and (K2), refrigerant fill level check switched off (as of MY 1997)

I8 With engine/climate control electric cooling fan

32 Auxiliary cooling fan not available as (of MY 1997)

1) Version coding menu.


3.7 Air Conditioning (A/C) Model 202 as of M.Y. 1996Diagnosis Diagnostic Trouble Code (DTC) Memory

i

The A/C pushbutton control module (N22) has DTC memory and data output. The diagnostictrouble codes and data are displayed via the temperature display window. The stored DTCs willremain in memory even with the vehicle battery disconnected.

The DTC memory differentiates between current and intermittent faults.

All DTCs can also be read with the Hand-Held Tester (HHT).

P83.40-0313-01Figure 1



Diagnosis Diagnostic Trouble Code (DTC) Memory

Preparations for DTC Readout

1. Review 11, 12, 14, 15, 20, 21, 23, 31, 33, 31

2. Connect HHT, see section 0, readout DTC's. DTC'S which aretransmitted via the instrument cluster (IC) series interface, must bereadout and the DTC's noted via the DTC memory in the instrumentcluster, finally erase the DTC's.

3. Ignition: ON

4. Temperature selector LO.

5. Within 20 seconds press 7 and 3 simultaneously for more than5 seconds.

6. The LED in 2 flashes and the display shows di A.

7. Press 8 repeatedly until all DTCs are displayed. Record each DTCas it is displayed. The current faults (refer to table) are displayed first,next, the intermittant failures (e.g. 45 5) are displayed in the displaywindow next to the 5 symbol. End will apppear after the last DTCis displayed. Press 8 again, dEL (delete, erase) will then appear indisplay.

8. To erase: Press ( and simultaneously for more than 5seconds and the display shows -- -.

To cancel erase: By pressing 8 the current faults will appearagain.

9. Turn ignition OFF to end test.




Special Tools

Hand-Held-Tester

965 589 00 01 00

Test cable

965 589 00 40 00




Diagnostic trouble code (DTC)

N22 APossible cause Test step/Remedy 1)

- - No malfunction in system

026 BI026 CAN communication Wiring.

226 BI226 In-car temperature sensor (B10/4) 23O 4.0

227 BI227 Outside temperature indicator temperature sensor (B14) 23O 10.0

228 BI228 Heater core temperature sensor (B10/1) 23O 7.0

230 BI230 Evaporator temperature sensor (B10/6) 23O 5.0

23I BI23I ECT sensor (B11/4 ) 23O 10.0

232 BI232 Refrigerant pressure sensor (B12) 23O 8.0

233 BI233 Refrigerant temperature sensor (B12/1) 23O 6.0

24I BI24I Refrigerant fill 23O 8.0, 6.0

4I6 BI4I6 Coolant circulation pump (A31m1) 23O 14.0

4I7 BI4I7 Left-side water valve (Y21y1) 23O 15.0

4I8 BI4I8 Right-side water valve (Y21y2) 23O 15.0

4I9 BI4I9 Electromagnetic clutch (A9k1) 23O 17.0

420 BI420 Idle speed increase -

42I BI42I Pulse module (N65) 23O 11.01) Observe Preparation for Test, see 22.




Diagnostic trouble code (DTC)

N22 APossible cause Test step/Remedy 1)

422 BI422 Serial interface (K1) 23O 10.0

45I BI45I Diverter flap (Y11/3) 23O 20.0

452 BI452 Blend air flap (Y11/3) 23O 21.0

453 BI453 Fresh/recirculated airflap (Y11/3) (long stroke) 23O 24.0

454 BI454 Fresh/recirculated airflap (Y11/3) (short stroke) 23O 25.0

455 BI455 Defroster outlet flap (Y11/3) (long stroke) 23O 18.0

456 BI456 Defroster outlet flap (Y11/3) (short stroke) 23O 19.0

457 BI457 Footwell flap (Y11/3) (long stroke) 23O 22.0

458 BI458 Footwell flap (Y11/3) (short stroke) 23O 23.0

459 BI459 Serial interface (K2) 23O 11.0

462 BI462 Wide open throttle (WOT) signal diesel engines -



3.7 Air Conditioning (A/C) Model 202 as of M.Y. 1996 Electrical Test Program Component Locations

P83.40-0325-06

Component locations in passenger compartment

Figure 1

B10/1 Heater core temperature sensor

B10/4 In-car temperature sensor with aspirator

B10/6x1 Evaporator temperature sensor connector

N22 A/C pushbutton control module



Electrical Test Program Component Locations

P83.40-0457-04

Component locations in enginecompartmentModel 210 shown

Figure 2

B11/4 CT sensor

P83.40-0456-04

Figure 3

N65/1 AIR control module




P83.40-0446-04


Figure 4

N76 Engine/climate control electric coolingfan control module

P83.40-0448-04

Figure 5

M4/3 Engine/climate control electric coolingfan




P83.30-0506-06

Component locations in engine compartmentModel 210 shown

Figure 6

M4 Auxiliary fan




P83.25-0268-04


Figure 7

M13 Coolant circulation pump


3.7 Air Conditioning (A/C) Model 202 as of M.Y. 1996 Electrical Test Program Connection of Components

P83.40-2068-06

Model 202 with Engine 104Engine 111 up to M.Y. 1997

Figure 1

A1 Instrument clusterA9 A/C compresserB11/4 ECT sensor (DIFI, IFI)B12 Refrigerant pressure sensorB12/1 Refrigerant temperature sensorL5 CKP sensorM4 Auxiliary fanN3 CFI control moduleN10/2 Combination relay moduleN22 A/C pushbutton control moduleN47 Traction systems control moduleN65/1 AIR control module



Electrical Test Program Connection of Components

P83.40-2070-06

Model 202 Engine 111 M.Y. 1997

Figure 2

A1 Instrument clusterA9 A/C compresserB11/4 ECT sensor (DIFI, IFI)B12 Refrigerant pressure sensorB12/1 Refrigerant temperature sensorL5 CKP sensorM4/3 Engine/climate control electric cooling fanN3 CFI control moduleN10/2 Combination relay moduleN22 A/C pushbutton control moduleN47 Traction systems control moduleN76 Engine/climate control electric cooling fan

control module




P83.40-0412-06

Model 202 Engine 111 M.Y. 1998

Figure 3

A1 Instrument clusterA9 A/C compresserB11/4 ECT sensor (DIFI, IFI)B12 Refrigerant pressure sensorB12/1 Refrigerant temperature sensorL5 CKP sensorM4/3 Engine/climate control electric cooling fanN3 CFI control moduleN10/1 Signal pick-up and activation module (SAM)

left frontN22 A/C pushbutton control moduleN76 Engine/climate control electric cooling fan

control module




P83.40-2069-06

Model 202 Engine 112

Figure 4

A1 Instrument clusterA9 A/C compresserB11/4 ECT sensor (DIFI, IFI)B12 Refrigerant pressure sensorB12/1 Refrigerant temperature sensorL5 CKP sensorM4 Auxiliary fanN3 CFI control moduleN10/1 Signal pick-up and activation module (SAM)

left frontN22 A/C pushbutton control moduleN65/1 AIR control module




P83.40-2086-06

Model 202 Connection of components forAuxiliary fan (M4) activationEngine 104Engine 111 up to M.Y. 1997

Figure 5

A1 Instrument clusterB11/4 ECT sensor (DIFI, IFI)B12 Refrigerant pressure sensorM4 Auxiliary fanN3 CFI control moduleN22 A/C pushbutton control moduleN47 Traction systems control moduleN65/1 AIR control module




P83.40-2087-06

Model 202 Connection of components forAuxiliary fan (M4) activationEngine 104Engine 111 up to M.Y. 1997

Figure 6

A1 Instrument clusterB11/4 ECT sensor (DIFI, IFI)B12 Refrigerant pressure sensorM4/3 Engine climate control electric cooling fanN3 CFI control moduleN22 A/C pushbutton control moduleN47 Traction systems control moduleN76 Engine/climate control electric cooling fan

control module




P83.40-2088-06

Model 202 Connection of components forAuxiliary fan (M4) activationEngine 111 as of M.Y. 1998Engine 112.920 as of M.Y. 1999

Figure 7

A1 Instrument clusterB11/4 ECT sensor (DIFI, IFI)B12 Refrigerant pressure sensorM4/3 Engine climate control electric cooling fanN3 CFI control moduleN10/1 Signal pick-up and activation module (SAM)

left frontN22 A/C pushbutton control moduleN47 Traction systems control moduleN76 Engine/climate control electric cooling fan

control module




P83.40-2078-06

Model 202 Connection of components for temperature regulation Models 202, 208

Figure 8

A1 Instrument clusterA32m1 Blower motorB10/1 Heater core temperature sensorB10/4 In-car temperature sensorB10/6 Evaporator temperature sensorB14 Outside temperature indicator temperature

sensorM13 Coolant circulation pumpN3 CFI control moduleN19 A/C pushbutton control moduleY21 Duovalve


3.7 Air Conditioning (A/C) Model 202 as of M.Y. 1996 Electrical Test Program Preparation for Test

1. Review 21, 22, document GF83.40-P-0001-02E and electricalwiring diagram: PE83.00-P-1100D,

2. Review section O,

3. Review 11, 12, 14, 15, 20, 31, 32, 41,

4. Remove A/C pushbutton control module (N22), see AR83.40-P-6350C.

iUpon completion of test, erase DTC memory from A/C pushbutton controlmodule (see 15).

Electrical wiring diagrams:Electrical Troubleshooting Manual, Model 202

Special Tools

18-pin and 12-pin CAN test cable

202 589 15 63 00

29-pin test cable

210 589 00 63 00

35-pin socket box

124 589 00 21 00

Test equipment; See MBUSA Standard Service Equipment Program

Description Brand, model, etc.

Multimeter 1) Fluke models 23, 77 III, 83, 85, 87

1) Available through the MBUSA Standard Equipment Program.



Electrical Test Program - Preparation for Test

P83.40-0314-06

Connection Diagram Socket BoxTest Cable: 202 589 15 63 00

Figure 1

001 Right connector, A/C pushbuttoncontrol module

002 Test cable003 Multimeter004 Socket boxN22 A/C pushbutton control module



Electrical Test Program - Preparation for Test

P83.40-0315-06

Connection Diagram Socket BoxTest Cable: 210 589 00 63 00

Figure 2

001 Right connector, A/C pushbuttoncontrol module

002 Test cable003 Multimeter004 Socket boxN22 A/C pushbutton control module



Electrical Test Program Test

O

ATest scope Test connection Test condition Nominal value Possible cause/Remedy

1.0 A/C pushbutton controlmodule (N22)Voltage supplyCircuit 30

19 w

N22k

c L 8

k on right connector(210 589 00 63 00).

11 14 V Wiring,O 1.1,Circuit 31

1.1 Circuit 30

o w

N22k

c L 8

k on right connector(210 589 00 63 00).

11 14 V Wiring,Circuit 31

2.0 Voltage supplyCircuit 15

19 w

N22k

c L 9

k on right connector(210 589 00 63 00).Ignition: ON

11 14 V Wiring.

3.0 Voltage supplyCircuit 15x

19 w

N22k

c L 7

k on left connector(210 589 00 63 00).Ignition: ON

11 14 V Wiring.

4.0 BI226 In-car temperature sensor (B10/4)with aspiratorResistance

23 w

N22k

b L 16

Ignition: OFFk on left connector(210 589 00 63 00).Disconnect N22 from k.

oC = k]10=19.0 21.020=11.9 13.030 =7.7 8.445 =4.2 4.6

Wiring,B10/4




O


5.0 BI230 Evaporator temperature sensor (B10/6)Resistance 23 w

N22k

b L 19


oC = k]10 = 5.2 5.820 = 3.2 3.630 = 2.0 2.345 = 1.1 1.25

Wiring,B10/6

6.0 BI233 Refrigerant temperaturesensor (B12/1)Resistance 23 w

N22k

b L 21


C = k ]20 = < 1340 = < 5.550 = < 3.760 = < 2.570 = < 1.8

Wiring,B12/1

7.0 BI228 Heater core temperaturesensor (B10/1), leftResistance 23 w

N22k

b L 17


oC = k]10=19.0 21.220=11.9 13.230 = 7.7 8.445 = 4.2 4.6

Wiring,B10/1

8.0 BI232 Refrigerant pressure sensor (B12)Voltage supply 23 w

N22k

c L 31

kon left connector(202 589 15 63 00).Ignition: ON

4.75 5.25 V Wiring,B12,N22




O


9.0 Diagnostic outputVoltage

o w

N22k

c L 15

kon left connector(202 589 15 63 00).Ignition: ON

11 14 V Wiring,N22

10.0 BI422 Serial Interface (K1)

23 w

N22k

c L 24

k on left connector(202 589 15 63 00).Ignition: ON

6 8 V Wiring.

11.0 Serial Interface (K2)

o w

N22k

c L 10

k on right connector(202 589 15 63 00).Ignition: ON

6 8 V Wiring.

12.0 BI42I Auxliary fan (M4)ActivationVoltage 19 w

N22k

c L 16

k on right connector(210 589 00 63 00).Ignition: ONPress 8 and k > 10secs.End test: Press 8 andk > 10 secs.

> 2 VAuxliary fans(M4) run.

Wiring,N22,N65




O


13.0 A/C Pushbutton controlmodule (N22), 12 V outputVoltage 19 w

N22k

c L 28

Ignition: ONk on right connector(210 589 00 63 00).

11 - 14 V Wiring,N22

14.0 BI4I6 Cooalnt circulation pump (M13)Resistance 20 w

N22k

b L 18

k on right connector (210 589 00 63 00).Ignition: OFFDisconnect N22 from k.

2 - 4 ] Wiring,M13

15.0 BI4I7BI4I8

Duovalve (Y21)Resistance

18 w

Y21k

b L 12

Ignition: OFFDisconnect N22 from k(210 589 00 63 00).

8 - 15 ] Wiring,Y21

16.0 Blower regulator (A32n1) ControlVoltage 19 w

N22k

c L 1

k on right connector (210 589 00 63 00).Ignition: ON5 MIN

MA> 0.7 V> 0.5 V

Wiring,A32




O


17.0 BI4I9 A/C compressor (A9)activationVoltage 19 w

N22k

c L 25

k on right connector (210 589 00 63 00).Engine: At IdleA/C compressor: 6A/C compressor: 3

< 1 V11 14 V

Wiring,N22

18.0 BI455 Switch over block (Y11/3),Defroster outletLong strokeVoltage

23 w

N22k

c L 18

k on right connector (210 589 00 63 00).Ignition: ONPress !

11 14 V Wiring,Y11/3

19.0 BI454 Switch over block (Y11/3),Defroster outletShort strokeVoltage

22 w

N22k

c L 18

k on right connector (210 589 00 63 00).Ignition: ONPress !


20.0 BI45I Switch over block (Y11/3),Diverter valve center ventVoltage

15 w

N22k

c L 18

k on right connector (210 589 00 63 00).Ignition: ONN22 display: "Lo"Press $





O


21.0 BI452 Switch over block (Y11/3),Blend air flap center ventVoltage

6 w

N22k

c L 18

k on right connector (210 589 00 63 00).Ignition: ONPress $


22.0 BI457 Switch over block (Y11/3),Footwell flaplong strokeVoltage

14 w

N22k

c L 18



23.0 BI457 Switch over block (Y11/3),Footwell flapshort strokeVoltage

13 w

N22k

c L 18






O


24.0 BI453 Switch over block (Y11/3),Fresh/recirculated air flap 80%Voltage

5 w

N22k

c L 18

k on right connector (210 589 00 63 00).Ignition: ONk is illuminated.


25.0 BI454 Switch over block (Y11/3),Fresh/recirculated air flap 20%Voltage

4 w

N22k

c L 18

k on right connector (210 589 00 63 00).Ignition: ONk is illuminated.



3.7 Air Conditioning (A/C) Model 202 as of M.Y. 1996 Pneumatic Test Program Component Locations

Figure 1

36 Vacuum distributor block

P83.40-0438-06



Pneumatic Test Program Component Locations

P83.40-0429-06

Figure 2

31 Check valve

35 Connnecter (passenger compartment)

A37 PSE control module

Y11 Switchover valve block (4 connections)

gr Grey

mgn Medium green

t Transparent



Pneumatic Test Program Component Locations

P83.40-0439-06

Figure 3

35 Connecter (passenger compartment)

36 Vacuum distributor block

38 Right defroster flap vacuum actuator

41 Diverter flap vacuum actuator

44 Fresh/recirculating air flap vacuum actuator

45 Left center outlet tempering flap vacuum actuator

46 Right center outlet tempering flap vacuum actuator

Y11/3 Valve block (8 connector)

hbl Light blue

drt Dark red

ge Yellow

mgn Medium green

rt Red

ws White

dgn Dark green


3.7 Air Conditioning (A/C) Model 202 as of M.Y. 1996 Pneumatic Test Program - Test


1. Review 11, 12, 14, 15, 20, 21, 31, 32, 41

2. Disconnect all vacuum lines at vacuum distributor block (36).

3. Check gray vacuum line to intake manifold for leaks.

Note:Permissible leakage of the elements with vacuum lines at 400 mbar vacuumper minute is 30 mbar.

Special Tools

Tester

201 589 13 21 00

Test equipment; See MBUSA Standard Service Equipment Program

Description Brand, model, etc.

Connector 124 805 04 44



Pneumatic Test Program Test

A. Vacuum Distributor Block, Vakuum Reservoir, Switchover Valve Block (Y11/3) Test

O Test scope Test connection Test condition Nominal value Possible cause/Remedy

1.0 Entire vacuum distributorblock

Connection P on vacuumtester.

Evacuate system with 300 mbar vacuum.

30 mbar pressure increase in 1 minute

Vacuum distributor block,O 1.1

1.1 Vacuum distributor block,check valve a

Connection 1 on vacuumtester.



Vacuum distributor block,O 1.2

1.2 Vacuum distributor block,check valve b

Connection 4 on vacuumtester.



Vacuum distributor block.

2.0 Vacuum reservoir with vacuum line

Red/gray vacuum line(connection 3) on vacuumtester.



Vacuum lines,Vacuum reservoir.

3.0 Switchover valveblock (Y11/3)

Ignition: OFFmedium green line(connection 5) on vacuumtester.



Vacuum line,Y11/3.




P83.40-0440-01

Figure 2

36 Vacuum distribution block


B. Vacuum system

1. Ignition: ON

2. Medium green line (connection 5) on vacuum tester.




B. Vacuum system Test


1.0 Defroster flap vacuumactuator, long stroke

Medium green line(connection 5) on vacuumtester.

Ignition: ONPress ! Evacuate system with 300 mbar vacuum.

30 mbar pressure increase in 1 minute.

Vacuum line,Vacuum actuator 38

1.1 Defroster flap vacuumactuator, short and longstroke


Ignition: ONPress ! Evacuate system with 300 mbar vacuum.



2.0 Diverter valve flapcenter vent


Ignition: ONPress $Temperature selector LOEvacuate system with 300 mbar vacuum.



3.0 Blend air flapcenter vent


Ignition: ONPress $ Evacuate with 300 mbar vacuum.


Vacuum line,Vacuum actuator 45 and 46

4.0 Footwell flap, long stroke Medium green line(connection 5) on vacuumtester.

Ignition: ONPress $ Evacuate system with 300 mbar vacuum.







4.1 Footwell flap vacuumelement, long and shortstroke.


Ignition: ONPress $Evacuate system with 300 mbar vacuum.



5.0 Fresh/recirculating air flapvacuum element, long stroke.


Ignition: ON2 IlluminatesEvacuate system with 300 mbar vacuum.



5.1 Fresh/recirculating air flapvacuum element, short andlong stroke.


Ignition: ON2 IlluminatesEvacuate system with 300 mbar vacuum.





Refrigeration System Test Program Component Locations

P83.30-0390-06

A/C Components locations

Figure 1

A High pressure connectionB Low pressure connectionB12 Refrigerant pressure sensorB12/1 Refrigerant temperature sensor1 A/C compressor2 High pressure vapor line to condenser3 Condenser4 High pressure liquid line to receiver/dryer5 Receiver/dryer7 Low pressure line to evaporator8 Expansion valve9 Evaporator10 Low pressure line to A/C compressor


3.7 Air Conditioning (A/C) Contents -...

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